Laser powder deposition weld rework for gas turbine engine non-fusion weldable nickel castings

Abstract

A method of reworking an aerospace component includes removing a casting defect from a component manufactured of a non-fusion weldable base alloy to form a cavity. The cavity is then at least partially filled with a multiple of layers of discrete laser powder deposition spots of a filler alloy. A cast component for a gas turbine engine includes a cast component non-fusion weldable base alloy with a cavity filled with a multiple of layers of laser powder deposition spots of a filler alloy. The filler alloy may be different than the non-fusion weldable base alloy. A layer of non-fusion weldable base alloy is at least partially within the cavity and over the filler alloy.

What is claimed is: 
     
       1. A method of reworking a component, comprising:
 removing a casting defect from a component manufactured of a non-fusion weldable base alloy to form a cavity; 
 at least partially filling the cavity with a multiple of layers of a multiple of laser powder deposition spots, each of the multiple of laser powder deposition spots formed of a filler alloy; 
 applying a non-fusion weldable base alloy cap at least partially within the cavity and over the filler alloy; and 
 applying a coating over the non-fusion weldable base alloy cap. 
 
     
     
       2. The method as recited in  claim 1 , wherein the filler alloy is a fusion weldable powder material. 
     
     
       3. The method as recited in  claim 2 , wherein the non-fusion weldable base alloy is a high gamma prime nickel based alloy. 
     
     
       4. The method as recited in  claim 2 , wherein the non-fusion weldable base alloy is a polycrystalline cast nickel base superalloy. 
     
     
       5. The method as recited in  claim 2 , wherein the non-fusion weldable base alloy is a polycrystalline cast nickel base superalloy. 
     
     
       6. The method as recited in  claim 1 , further comprising electro-spark depositing the non-fusion weldable base alloy cap. 
     
     
       7. The method as recited in  claim 6 , wherein the non-fusion weldable base alloy cap is about 0.010 inches (0.25 mm) thick. 
     
     
       8. The method as recited in  claim 1 , further comprising casting the component of the non-fusion weldable base alloy. 
     
     
       9. The method as recited in  claim 8 , further comprising casting the component to form a portion of a mid-turbine frame. 
     
     
       10. The method as recited in  claim 8 , wherein removing the casting defect results in a through hole, and sealing the through hole with a backing prior to at least partially filling the cavity. 
     
     
       11. A cast component for a gas turbine engine, comprising:
 a cast component manufactured of non-fusion weldable base alloy with a cavity at least partially filled with a multiple of layers of a multiple of laser powder deposition spots, each of the multiple of laser powder deposition spots formed of a filler alloy, wherein the filler alloy is different than the non-fusion weldable base alloy; 
 a non-fusion weldable base alloy cap at least partially within the cavity and over the filler alloy; and 
 a coating over the non-fusion weldable base alloy cap. 
 
     
     
       12. The cast component as recited in  claim 11 , wherein the non-fusion weldable base alloy is a high gamma prime nickel based alloy. 
     
     
       13. The cast component as recited in  claim 11 , wherein the non-fusion weldable base alloy is a polycrystalline cast nickel base superalloy. 
     
     
       14. The cast component as recited in  claim 11 , wherein the non-fusion weldable base alloy is a polycrystalline cast nickel base superalloy. 
     
     
       15. The cast component as recited in  claim 11 , wherein the non-fusion weldable base alloy cap is about 0.010 inches (0.25 mm) thick. 
     
     
       16. The cast component as recited in  claim 15 , wherein the cast component as a portion of a mid-turbine frame.